Component mounting machine

Abstract

The component mounting apparatus includes a component delivery unit, a chuck ( 13 ) provided on the component delivery unit, a component transfer unit ( 19 ) for receiving a component held by the chuck ( 13 ), and a head ( 20 ) for receiving the component held by the component transfer unit ( 19 ). The head ( 20 ) includes a main head body ( 80 ), a vertically moving mechanism ( 81 ) for the main head body ( 80 ), insertion nails ( 68 ) provided at a bottom portion of the main head body ( 80 ), an opening/closing mechanism ( 82 ) for the insertion nails ( 68 ), and a turning mechanism ( 83 ) for moving the insertion nails ( 68 ) in forward and backward directions. A cam plate ( 84 ) constituting the turning mechanism ( 83 ) is mounted detachably on the main head body ( 80 ).

What is claimed is:  
     
       1. A component mounting apparatus comprising: 
       a component delivery unit;  
       a chuck provided on said component delivery unit;  
       a component transfer unit for receiving a component held by said chuck; and  
       a head for receiving the component held by said component transfer unit, said head including:  
       a main head body;  
       a manipulator connected to said main head body and operable to move in a vertical direction;  
       an insertion nail provided at a bottom portion of said main head body;  
       an opening/closing mechanism for opening and closing said insertion nail; and  
       a turning mechanism for moving said insertion nail in forward and backward directions, wherein said turning mechanism comprises a plurality of cam plates, each of said cam plates having a cam surface and being operable to be detachably mounted to said main head body, said cam plates having differently-shaped cam surfaces corresponding to different paths of movement of said insertion nail such that when a first one of said cam plates is detachably mounted to said main head body, said turning mechanism is operable to move said insertion nail in forward and backward directions along a first one of said different paths of movement corresponding to said first one of said cam plates.  
     
     
       2. The component mounting apparatus according to  claim 1 , wherein said manipulator comprises: 
       an external axle attached to a top of said main head body;  
       an internal axle arranged inside said external axle; and  
       a mount plate attached to a lower end of said internal axle, said cam plate being detachably mounted to said mount plate.  
     
     
       3. The component mounting apparatus according to  claim 1 , further comprising a rotary body engaged to said cam plate so as to be rotatable in forward and backward directions of said main head body, wherein said insertion nail comprises a first insertion nail attached to said rotary body, and said insertion nail also comprises a second insertion nail rotatably attached to said first insertion nail. 
     
     
       4. The component mounting apparatus according to  claim 3 , wherein an upper portion of said second insertion nail and a portion of a driving lever corresponding to said upper portion make contact with each other via a cam surface. 
     
     
       5. The component mounting apparatus according to  claim 3 , wherein said first insertion nail and said second insertion nail each have at least three grip nails formed at a distal end of each of said first insertion nail and said second insertion nail. 
     
     
       6. The component mounting apparatus according to  claim 5 , wherein one of said grip nails at one side of said second insertion nail has a narrower intervening space and greater flexibility than any of said remaining grip nails of said second insertion nail. 
     
     
       7. The component mounting apparatus according to  claim 3 , wherein said first insertion nail and said second insertion nail are engaged together, and a center of said second insertion nail is pivotally supported by a center of said first insertion nail. 
     
     
       8. The component mounting apparatus according to  claim 1 , further comprising: 
       a pusher for pressing a top of the component held by said insertion nail; and  
       a catch pin for receiving a terminal extending downward from the component, wherein said catch pin is adapted to receive a lower end of the terminal underneath a substrate on which the component is to be mounted.  
     
     
       9. The component mounting apparatus according to  claim 8 , wherein said catch pin has a diameter greater than a diameter of a through-hole provided in the substrate. 
     
     
       10. The component mounting apparatus according to  claim 1 , wherein said cam surface of each of said cam plates has a slope length, said cam plates having different slope lengths, said turning mechanism further comprising a cam follower linked to said insertion nail, said cam follower being arranged so as to contact and move along said cam surface of one of said cam plates. 
     
     
       11. The component mounting apparatus according to  claim 1 , wherein said insertion nail is arranged adjacent to said cam plate of said turning mechanism such that said turning mechanism engages said insertion nail. 
     
     
       12. A component mounting apparatus comprising: 
       a component delivery unit;  
       a chuck provided on said component delivery unit;  
       a component transfer unit for receiving and holding a component held by said chuck, the component having a lead terminal extending downwardly;  
       a head for receiving and holding the component held by said component transfer unit, and for moving the lead terminal above a through-hole of a substrate in which the lead terminal is to be inserted; and  
       a pusher for pressing down the component held by said head toward the substrate;  
       said head including:  
       a main head body;  
       a manipulator connected to said main head body and operable to move in a vertical direction;  
       an insertion nail provided at a bottom portion of said main head body;  
       an opening/closing mechanism for opening and closing said insertion nail; and  
       a turning mechanism for moving said insertion nail in forward and backward directions, wherein said turning mechanism comprises a plurality of cam plates, each of said cam plates having a cam surface and being operable to be detachably mounted to said main head body, said cam plates having differently-shaped cam surfaces corresponding to different paths of movement of said insertion nail such that when a first one of said cam plates is detachably mounted to said main head body, said turning mechanism is operable to move said insertion nail in forward and backward directions along a first one of said different paths of movement corresponding to said first one of said cam plates,  
       said pusher being operable to hold in a standby position above the component before coming in contact with and pressing down the component toward the substrate, and said pusher being operable to set the standby position according to the height of the component held by said head.  
     
     
       13. The component mounting apparatus according to  claim 12 , further comprising a catch pin provided under a through-hole of the substrate for supporting a lower end of the lead terminal of the component. 
     
     
       14. The component mounting apparatus according to  claim 12 , wherein said pusher is operable to set the standby position using a calculation based on the height of the component to be mounted. 
     
     
       15. The component mounting apparatus according to  claim 12 , wherein said pusher is arranged to contact a first end of a first lever, a fulcrum of said first lever being supported axially by a second lever, a second end of said first lever being arranged to contact a first cam, and an end of said second lever being arranged to contact a second cam. 
     
     
       16. The component mounting apparatus according to  claim 15 , wherein said first cam has a rotary axle coaxial with a fulcrum of said second lever. 
     
     
       17. The component mounting apparatus according to  claim 12 , wherein said cam surface of each of said cam plates has a slope length, said cam plates having different slope lengths, said turning mechanism further comprising a cam follower linked to said insertion nail, said cam follower being arranged so as to contact and move along said cam surface of one of said cam plates. 
     
     
       18. A component mounting apparatus comprising: 
       a component delivery unit;  
       a chuck provided on said component delivery unit;  
       a component transfer unit for receiving and holding a component having a lead terminal held by said chuck;  
       a head for receiving the component held by said component transfer unit;  
       a vertically-moving mechanism for moving said head;  
       a table disposed below said head for supporting a substrate; and  
       an anvil mechanism disposed under said table,  
       said head including:  
       a main head body;  
       a manipulator connected to said main head body and operable to move in a vertical direction;  
       an insertion nail provided at a bottom portion of said main head body;  
       an opening/closing mechanism for opening and closing said insertion nail; and  
       a turning mechanism for moving said insertion nail in forward and backward directions, wherein said turning mechanism comprises a cam plate detachably mounted to said main head body;  
       said anvil mechanism including:  
       a mounting base provided with two slant surfaces opposed to each other;  
       a fixed blade mounted on a first slant surface of said slant surfaces of said mounting base; and  
       a movable blade mounted on a second slant surface of said slant surfaces of said mounting base, wherein said fixed blade is fixed to said first slant surface of slant surfaces of said mounting base after said fixed blade is slid and set in position.  
     
     
       19. The component mounting apparatus according to  claim 18 , further comprising an operating rod disposed under said mounting base, wherein said operating rod is linked to said movable blade. 
     
     
       20. The component mounting apparatus according to  claim 19 , wherein said operating rod and said movable blade are linked together by a coupling lever supported axially by said mounting base. 
     
     
       21. The component mounting apparatus according to  claim 19 , wherein said operating rod has two flanges on a periphery of a top portion of said operating rod, said flanges being spaced apart a predetermined distance, and an upper one of said flanges has a cut-back portion. 
     
     
       22. The component mounting apparatus according to  claim 19 , wherein said operating rod has a cylindrical shape, and a lead terminal supporter is provided in said cylindrically shaped operating rod so as to be coaxial with said operating rod and vertically movable. 
     
     
       23. The component mounting apparatus according to  claim 22 , wherein said lead terminal supporter comprises a cylinder having a catch pin arranged in an opening in an upper end of said cylinder so as to protrude upwardly. 
     
     
       24. The component mounting apparatus according to  claim 23 , further comprising a cap having an inner peripheral female thread and having an opening on a top surface, said cap being screwed removably on said upper end of said cylinder. 
     
     
       25. The component mounting apparatus according to  claim 23 , wherein a supporting body is provided to bridge across said opening in said upper end of said cylinder, and said catch pin is mounted on said supporting body. 
     
     
       26. The component mounting apparatus according to  claim 25 , wherein said supporting body has a substantially flat shape, and has a supporting pin arranged horizontally across said substantially flat supporting body, and said catch pin is arranged so as to have a lower end abutting said supporting pin. 
     
     
       27. The component mounting apparatus according to  claim 26 , wherein an upper peripheral portion of said cylinder has a male thread, and a notch extends from said upper end of said cylinder vertically downward through said male thread, and said supporting pin is engaged in said notch. 
     
     
       28. The component mounting apparatus according to  claim 27 , wherein said supporting pin is engaged in a lower part of said notch, and a projection on said supporting body is engaged in an upper part of said notch. 
     
     
       29. The component mounting apparatus according to  claim 18 , wherein a groove is formed on at least one of an upper surface of said movable blade and a lower surface of said movable blade. 
     
     
       30. The component mounting apparatus according to  claim 29 , wherein a groove is formed on an upper surface of said movable blade, and a through hole extends from a lower end of said groove. 
     
     
       31. The component mounting apparatus according to  claim 18 , wherein said movable blade is operable to slide along said second slant surface of said slant surfaces to a top position that is above an anticipated point where said movable blade meets with said fixed blade, and said fixed blade is fixed at a position whereat said fixed blade comes in contact with said movable blade at said top position. 
     
     
       32. The component mounting apparatus according to  claim 18 , wherein said cam plate of said turning mechanism is one of a plurality of interchangeable cam plates having different shapes corresponding to different paths of movement of said insertion nail, any one of said cam plates being detachably mounted to said main head body such that said turning mechanism is operable to move said insertion nail along a desired one of said paths of movement of said insertion nail corresponding to the shape of said any one of said cam plates. 
     
     
       33. A component mounting apparatus comprising: 
       a component delivery unit having an annular shape;  
       a plurality of chucks provided along an outer peripheral surface of said component delivery unit, said chucks being adapted to hold components;  
       a plurality of component supply units provided on an external side of said plurality of chucks;  
       a chain of taped components supplied by said plurality of component transfer units;  
       a plurality of component transfer units for receiving and holding said components held by said chucks; and  
       a head for receiving said components held by said component transfer units;  
       wherein said chain of taped components consists of said components, each of said components having an element and at least two lead terminals connected to said element, said components being spaced and taped at regular intervals;  
       wherein said component supply units supply said chain of taped components to said chucks so that said components are positioned with an element side up and a lead terminal side down, and so that said components are aligned in a single row.  
     
     
       34. The component mounting apparatus according to  claim 33 , wherein said plurality of component supply units are arranged so as to be side-by-side. 
     
     
       35. The component mounting apparatus according to  claim 33 , wherein each of said component supply units has a first chuck release for opening said chucks. 
     
     
       36. The component mounting apparatus according to  claim 35 , wherein said chuck has a first side adjacent to said component supply unit, said chuck having a hook on said first side linked to said first chuck release. 
     
     
       37. The component mounting apparatus according to  claim 36 , wherein said chuck has an extended portion extending toward a back surface of said belt from a second side of said chuck opposite said first side having said hook, and a second chuck release is linked to said extended portion. 
     
     
       38. The component mounting apparatus according to  claim 35 , wherein each of said component supply units has a feeder of said chain of taped components and a cam for actuating said feeder of said chain of taped components, said cam having a chuck opening cam surface for actuating said first chuck release. 
     
     
       39. The component mounting apparatus according to  claim 38 , further comprising a transmission mechanism between said first chuck release and said chuck opening cam surface of said cam, wherein said transmission mechanism is operable to actuate said first chuck release only when said cam shifts toward a first direction. 
     
     
       40. The component mounting apparatus according to  claim 38 , wherein each of said component supply units has a taping member cutting blade between said feeder and said chuck, said cam having a cutting blade open/close cam surface and a cutting blade shift cam surface for actuating said taping member cutting blade. 
     
     
       41. The component mounting apparatus according to  claim 40 , wherein each of said component supply units has at least one driving mechanism for shifting said cam a first amount of movement and a second amount of movement, which is greater than said first amount of movement, and said first amount of movement actuates said first chuck release and said feeder. 
     
     
       42. The component mounting apparatus according to  claim 41 , wherein said cam is linked to said taping member cutting blade such that, when said at least one driving mechanism shifts said cam said second amount of movement, said taping member cutting blade is closed. 
     
     
       43. The component mounting apparatus according to  claim 41 , wherein each of said component supply units has an element detector for detecting a presence or an absence of an element in said chain of taped components, and said driving mechanism is operable to shift said cam said first amount of movement for a plurality of times when said element detector detects the absence of an element. 
     
     
       44. The component mounting apparatus according to  claim 33 , wherein said component delivery unit comprises a flexible belt, said belt having a back surface and having ditches and ridges on said back surface for positioning of said chucks. 
     
     
       45. The component mounting apparatus according to  claim 44 , wherein said belt has a plurality of chuck retainers spaced apart at regular intervals, and each of said plurality of chuck retainers has a chuck. 
     
     
       46. The component mounting apparatus according to  claim 45 , wherein each of said plurality of chuck retainers has a guide piece, and said guide piece engages a guide rail. 
     
     
       47. The component mounting apparatus according to  claim 46 , wherein at least one of an upper end and a lower end of each of said plurality of chuck retainers has an extended portion extending toward said back surface of said belt, said guide piece being formed on said extended portion. 
     
     
       48. The component mounting apparatus according to  claim 33 , wherein said chuck comprises a pair of nails operable to be moved apart from each other so as to open said chuck, and comprises an elastic body attached to an inside face of one of said pair of nails. 
     
     
       49. The component mounting apparatus according to  claim 33 , wherein said chuck comprises a fixed nail and a movable nail, said movable nail being operable to move with respect to said fixed nail so as to open said chuck, and an elastic body is attached to an inside face of one of said movable nail and said fixed nail. 
     
     
       50. The component mounting apparatus according to  claim 49 , wherein said elastic body is attached to one of said fixed nail and said movable nail by a pin penetrating through said elastic body. 
     
     
       51. The component mounting apparatus according to  claim 33 , further comprising a cutting blade for cutting an extra length of a taping member, and further comprising an extra-length detector positioned on said component delivery unit at a downstream side of a component supply location adjacent to said component supply unit, said extra-length detector being operable to detect a presence or an absence of an extra length of a taping member, wherein said extra-length detector actuates said cutting blade for cutting an extra length of a taping member so as to cut the extra length of said taping member to a predetermined length. 
     
     
       52. The component mounting apparatus according to  claim 51 , wherein said cutting blade for cutting an extra length of a taping member is operable to move from a lower position to an upper position so as to cut the extra length of said taping member, and is operable to return to said lower position after the cutting. 
     
     
       53. The component mounting apparatus according to  claim 33 , further comprising a polarity flipper unit for flipping the polarity of said components, said polarity flipper unit being arranged on said component delivery unit at a downstream side of the component supply location adjacent to said component supply unit, said polarity flipper unit being freely movable toward and away from said component delivery unit. 
     
     
       54. The component mounting apparatus according to  claim 53 , wherein said polarity flipper unit is positioned at a downstream side of said second cutting blade. 
     
     
       55. The component mounting apparatus according to  claim 33 , further comprising a hold position correction unit for correcting a position of said lead terminals of a component held by said chuck, said hold position correction unit being arranged on said component delivery unit at a downstream side of the component supply location adjacent to said component supply unit. 
     
     
       56. The component mounting apparatus according to  claim 55 , further comprising a polarity flipper unit for flipping the polarity of said components, said polarity flipper being arranged on said component delivery unit at a downstream side of the component supply location adjacent to said component supply unit, wherein said hold position correction unit is provided at a downstream side of said polarity flipper unit. 
     
     
       57. The component mounting apparatus according to  claim 55 , wherein said hold position correction unit comprises: 
       a positioning base for supporting a bottom edge of said chain of taped components;  
       a holder for holding said chain of taped components by pressing two sides of said chain of taped components in a direction orthogonal to a longitudinal direction of said chain of taped components; and  
       a push body for shifting a component of said chain of taped components by pushing one of said lead terminals of said component in the longitudinal direction of said chain of taped components.  
     
     
       58. The component mounting apparatus according to  claim 55 , further comprising a lead terminal cutting blade provided on said component delivery unit at a downstream side of said hold position correction unit, said lead terminal cutting blade being operable to cut said lead terminal, said lead terminal cutting blade being freely movable toward and away from said component delivery unit. 
     
     
       59. The component mounting apparatus according to  claim 58 , wherein said lead terminal cutting blade comprises a pair of blades movable with respect to each other so as to open said lead terminal cutting blade, each of said pair of blades having a distal end with a tapered lower surface, and said lead terminal cutting blade is arranged so that an upper edge of said chain of taped components contacts said tapered surfaces. 
     
     
       60. The component mounting apparatus according to  claim 33 , wherein each of said component transfer units is operable to transfer said component held by one of said chucks to said head, each of said component transfer units comprising two grip nails for holding a lower portion of said lead terminals of said component, and a support nail for supporting an upper portion of said lead terminals. 
     
     
       61. The component mounting apparatus according to  claim 60 , wherein a first one of said grip nails and said support nail are integrated, and a second one of said grip nails is arranged to be freely movable with respect to said first one of said grip nails integrated with said support nail. 
     
     
       62. The component mounting apparatus according to  claim 61 , wherein said head includes an insertion nail for gripping a portion of said lead terminals of said component located between said grip nails and said support nail. 
     
     
       63. A component mounting apparatus comprising: 
       a component delivery unit;  
       a chuck provided on said component delivery unit and operable to hold a component;  
       a component transfer unit for receiving and holding the component held by said chuck; and  
       a head for receiving the component held by said component transfer unit, said head including:  
       a main head body;  
       a manipulator connected to said main head body and operable to move in a vertical direction;  
       an insertion nail provided at a bottom portion of said main head body;  
       a first opening/closing mechanism for opening and closing said insertion nail; and  
       a first turning mechanism for moving said insertion nail in forward and backward directions, wherein said turning mechanism comprises a cam plate detachably mounted to said main head body;  
       said component transfer unit including:  
       a transfer chuck for receiving and holding the component held by said chuck on said component delivery unit;  
       a second turning mechanism for rotating said transfer chuck;  
       a shifting mechanism for shifting said transfer chuck toward an inside and an outside of a rotational arc of said transfer chuck; and  
       a second opening/closing mechanism for opening or closing said transfer chuck after said transfer chuck is shifted to the inside or the outside of the rotational arc of said transfer chuck by said shifting mechanism,  
       wherein a rotary axle of said second turning mechanism, a driving axle of said shifting mechanism, and an opening/closing axle of said second opening/closing mechanism are coaxial.  
     
     
       64. The component mounting apparatus according to  claim 63 , further comprising a third opening/closing mechanism for opening or closing said transfer chuck, in addition to said second opening/closing mechanism driven by said opening/closing axle. 
     
     
       65. The component mounting apparatus according to  claim 63 , wherein said transfer chuck comprises two grip nails for holding a lower portion of a lead terminal of the component held by said transfer chuck, and a support nail for supporting an upper portion of the lead terminal. 
     
     
       66. The component mounting apparatus according to  claim 65 , wherein a first one of said grip nails and said support nail are integrated, and a second one of said grip nails is arranged to be freely movable with respect to said first one of said grip nails integrated with said support nail. 
     
     
       67. The component mounting apparatus according to  claim 63 , further comprising: 
       a rotary plate to be rotated by said opening/closing axle of said second opening/closing mechanism; and  
       a third opening/closing mechanism for opening and closing said transfer chuck by a rotary movement of said rotary plate, both said rotary plate and said third opening/closing mechanism being arranged between said opening/closing axle and said transfer chuck, wherein said opening/closing axle biases said rotary plate for generating said rotary movement.  
     
     
       68. The component mounting apparatus according to  claim 63 , further comprising a shift lever between said driving axle of said shifting mechanism and said transfer chuck, said shift lever being biased by said driving axle so as to shift said transfer chuck toward the inside and the outside of the rotational arc of said transfer chuck. 
     
     
       69. The component mounting apparatus according to  claim 63 , wherein said cam plate of said first turning mechanism is one of a plurality of interchangeable cam plates having different shapes corresponding to different paths of movement of said insertion nail, any one of said cam plates being detachably mounted to said main head body such that said turning mechanism is operable to move said insertion nail along a desired one of said paths of movement of said insertion nail corresponding to the shape of said any one of said cam plates. 
     
     
       70. A component mounting apparatus comprising: 
       a component delivery unit;  
       a chuck provided on said component delivery unit and operable to hold a component;  
       a component transfer unit for receiving and holding the component held by said chuck;  
       a head for receiving the component held by said component transfer unit, and for mounting the component on a substrate positioned on a positioning table;  
       a rail for guiding the substrate on said positioning table; and  
       a transfer mechanism for transferring the substrate to said positioning table while being guided by said rail, said head including:  
       a main head body;  
       a manipulator connected to said main head body and operable to move in a vertical direction;  
       an insertion nail provided at a bottom portion of said main head body;  
       an opening/closing mechanism for opening and closing said insertion nail; and  
       a turning mechanism for moving said insertion nail in forward and backward directions, wherein said turning mechanism comprises a cam plate detachably mounted to said main head body;  
       said transfer mechanism including:  
       a shaft holder;  
       a transfer shaft operable to move freely in and out from said shaft holder toward said positioning table;  
       a transfer pin provided at a first end of said transfer shaft closest to said positioning table so as to extend toward the substrate;  
       a biasing device for biasing said transfer pin toward the substrate; and  
       a pin shifting unit provided at a first end of said shaft holder closest to said positioning table for shifting said transfer pin to a side of said transfer shaft opposite to the substrate against a biasing force of said biasing device.  
     
     
       71. The component mounting apparatus according to  claim 70 , wherein said transfer pin is operable to slide on an axle arranged at said first end of said transfer shaft closest to said positioning table so as to extend toward the substrate, said biasing device comprising a spring linked to said transfer pin, said pin shifting unit comprising: 
       a lever provided at said first end of said shaft holder closest to said positioning table; and  
       a lever actuator linked to a first end of said lever, and a second end of said lever being linked to said transfer pin.  
     
     
       72. The component mounting apparatus according to  claim 70 , wherein said turning mechanism is one of a plurality of interchangeable cam plates having different shapes corresponding to different paths of movement of said insertion nail, any one of said cam plates being detachably mounted to said main head body such that said turning mechanism is operable to move said insertion nail along a desired one of said paths of movement of said insertion nail corresponding to the shape of said any one of said cam plates.